Manufacturing Plus Quality Equals Reliability

Manufacturing Operations

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The manufacturing operations at CTT are highly integrated into all facets of the production build.
CTT maintains manufacturing operations within its Sunnyvale, California headquarters. These offices are staffed with engineering and materials support personnel that manage the day-today activities.
Having built thousands of products with power levels that range from a few watts to 1 kW, CTT has become a leader in solidstate microwave amplification.
CTT’s U.S.-based, 45,000 square-foot manufacturing facility offers a complete solution in the production of microwave integrated circuits.
Moreover, CTT’s facility was specifically designed to accommodate the unique requirements of hybrid microwave integrated circuit manufacturing conforming to MIL-PRF-38534.
Another important factor differentiating the CTT facility from other manufacturers is the availability of comprehensive microwave frequency test capabilities. This offers the customer to choose from either “standard” testing procedures or to customize testing to meet stringent system requirements.
CTT’s microwave testing utilizes the latest in network analysis tools. One of the primary strengths of CTT’s integrated circuit manufacturing is the ability to mix and match technologies to best meet the requirements of a particular application.

Commitment

CTT is committed to provide the highest level of reliability in its products. This is demonstrated by the extremely low number of repairs that the company receives.
Every product that CTT delivers strictly adheres to active de-rating criteria, thermal design consideration and proven manufacturing techniques established by CTT’s engineering and quality departments as well as those required by it’s suppliers.
During development phase, manufacturing operations perform product planning that includes design verification, supplier selection, manpower analysis, equipment needs and master scheduling.
Once a product is committed to the production department, production control monitors material suppliers and work-inprocess to ensure that any issues effecting the delivery commitments are addressed and corrected immediately.
Automation is used extensively all through the manufacturing process wherever possible.

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Quailty

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CTT is committed to the concept that quality must be designed in and not inspected into the product. The quality engineers review all designs for compliance to CTT’s quality and workmanship standards and assist design engineering in the selection of suppliers and components.
Inspection points throughout the manufacturing process are maintained and deviations analyzed and controlled through TQM and SPC programs to ensure a consistent manufacturing process.
To assure the highest level of reliability, CTT has implemented its own screening program derived from MIL-PRF-38534. Custom screening procedures are available on special request.
CTT’s quality and process control systems are approved to AS9100C / ISO 9001:2008 and JSTDs. Test and measurement equipment is calibrated in accordance with MIL-STD-45662 and ANZI-Z-540.
CTT is an AS9100C / ISO 9001:2008 Registered company and has received numerous supplier excellence awards for quality and performance.

Modern 45,000 Square-Foot Facility

Contains 12,000 Square-Feet of Class 1,000 and Class 10,000 Clean Rooms, and houses a computer-controlled, fully automated, robotic manufacturing operation comprising of:
► Multiple Pick-and-Place Machines whose Capabilities Accommodate:

• Hybrid Microwave ICs
• Surface-Mount Components
• Leaded Components

► The Latest Automated Wire Bond Machines Programmed for:

• 0.5 to 0.7 mil Wire Bonding
• 2 to 25 mil Ribbon Bonding

► Programmable Epoxy Dispensers

• Conductive Epoxy Attachment

► Component Mounting

• Batch and Continuous Flow
• Eutectic Component Attach
• Lead-Free Solder Available

Inventory Control

► Full Nitrogen Containment (to Preserve Solderability and Bondability)
► Project Stock Accounting
► Component and Assembly Lot Number Control
► Bonded Customer Storage

Material Management

► Project Availability and Yield Analysis
► Supplier Delivery, Pricing and Cost Performance Auditing
► Standalone Materials Procurement Group
► Project Target Goals and Budget Management

Product Test, Evaluation and Analysis

► Solderability Test and Analysis
► Optical Microscopy
► Electron Scanning Microscopy (10X to 1500X)
► Mechanical Tolerance and Testing
► Thermal and Imaging Analysis
► Surface and Wire Insulation Resistance
► Plating Thickness Measurement
► EMI Testing
► Equipment Calibration Traceability to NIST
► Available Environmental Testing to: MIL-STD-810 / MIL-STD-202 / MIL-E-5400
► Quality System: AS9100C / ISO 9001:2008
► Hybrid Construction Conforms to MIL-PRF-38534

Production Testing

► Analog and Digital Control Electronic Test
► Frequencies to 45 GHz
► Microwave Power to 1 kW

 

Electrostatic Discharge Protection Area (EPA)

► 3-Dimensional ESD-Controlled Work Areas
► Periodic Monitoring and Testing
► Continuously Monitored Ionization of Air
► Conductive Flooring Materials

CTT Screening Program

Test Method Test Condition
Pre-Cap Visual Inspection 2017, 2010 CTT Inspection Procedure #604003002
Stabilization Bake +125°C, 24 hours
Thermal Cycle 101.5 -55°C to +125°C, 5 cycles
Burn-In 1015 C 24 Hrs @ +85°C
Acceleration 2001.2 C 5000 Gs Y1 Axis
Seal Test 1014 C (Gross-Leak Only)
Final Electrical CTT Standard ATP #601003024
External Visual Inspection 2009 Customer Specs CTT QA Procedure #604006810